Anti-flame polystyrene composition containing flame-retarding halogenated compounds

ABSTRACT

NOVEL HALOGENIDES OF A REACTION PRODUCT OF A PHENOL, ALCOHOL, FATTY ACID, THIOPHENOL OR MERCAPTANE WITH A GLYCIDYL ETHER, GLYCIDYL ESTER OR GLYCIDYL THIOETHER AND, IF NECESSARY, AN ALKYLENE OXIDE OR ALKYLENE SULFIDE ARE EXCELLENT FLAME-RETARDING AGENTS FOR POLYSTYRENE AND A POLYSTYRENE COMPOSITION CONTAINING SAID HALOGENATED COMPOUND IS SELF-EXTINGUISHABLE AND RESISTANT TO WEATHER AND DISCOLORATION WITH LAPSE OF TIME.

U.S. Cl. 260-25 Fl 18 Claims ABSTRACT OF THE DISCLOSURE Novel halogenides of a reaction product of a phenol, alcohol, fatty acid. thiophenol or mercaptane with a glycidyl ether, glycidyl ester or glycidyl thioether and, if necessary, an alkylene oxide or alkylene sulfide are excellent flame-retarding agents for polystyrene and a polystyrene composition containing said halogenated compound is self-extinguishable and resistant to weather and discoloration with lapse of time.

CROSS-REFERENCE TO RELATED APPLICATION This application is a continuation-in-part application of application Ser. No. 764,307 filed Oct. 1, 1968, now abandoned.

The present invention relates to a novel halogenated compound which is a flame-retarding agent for polystyrene and an anti-flame polystyrene composition containing the same. More particularly, the present invention relates to a halogenide of a reaction product of a phenol, alcohol, fatty acid, thiophenol or mercaptane with a glycidyl ether, glycidyl ester or glycidyl thioether and, if necessary, an alkylene oxide or alkylene sulfide, and to composition of polystyrene and said halogenated compound as a flameretarding agent.

With recent rapid development of industry, organic synthetic high polymers have become applied to many uses, such as decorations, building materials, daily necessaries, constructions, buildings and heat-insulating materials in industry. Polystyrene is excellent in transparency, electric properties and thermoplasticity, and hence has often and much been used in the above-mentioned various fields.

However, in general, organic synthetic high polymers are combustible, and hence, once it is burnt, various fatal dangers are encountered. Recently, it has been desired that polystyrene have not only such excellent properties but also be non-combustible, and research on various antiflame polystyrene has been done. For example, halogenated hydrocarbons, such as 1,1,2,2-tetrabromoethane, 1,2-dichloro-1,2,3,4-tetrachloroethane, 1,2-dibromoethane (Japanese patent publication No. 5,739/62), 2-chloro 1,2,3,4-tetrabromobutane (Japanese patent publication No. 20,216/66) and the like, haloalkyl phosphates, such as tris-(2,3-di=bromopropyl) phosphate (Japanese patent publication No. 6,788/58) and the like and acetals or ethers of 2,3-dibromopropanol-l (Japanese patent publication No. 7,089/ 60) are known as flame-retarding agents for polystyrene.

However, many of them are not applicable in practice, because some must be used in a large amount, some have low weather-resistance and hence cause discoloration and deterioration of articles containing the same with the lapse of time, and some are expensive. Further, when some of the known flame-retarding agents are incorponited States Patent Patented May 2, 1972 rated into polystyrene, the softening point of the resulting uniform composition becomes lower than that of polystyrene itself, and some flame-retarding agents, when mixed with polystyrene and subjected to foaming, produce only a foam having a low degree of expansion which is a fatal defect for polystyrene foam. Some other flame retarding agents have low boiling points and hence are volatile, and polystyrene rendered anti-flame by treating it with such flame-retarding agent is, therefore, returned to the original combustible state with the lapse of time because the flame-retarding agents are volatilized with the lapse of time. Such a polystyrene composition is difiicult to have permanent anti-flame property.

An object of the present invention is to provide a novel halogenated compound which can impart anti-flame properties to polystyrene without impairing the physical properties of polystyrene itself and which has no abovementioned defects.

Another object of the present invention is to provide an anti-flame polystyrene composition containing a novel, flame-retarding, halogenated compound.

A further object of the present invention is to provide an anti-flame, foamed polystyrene composition containing a novel flame-retarding, halogenated compound.

A still further object of the present invention is to provide a foamed polystyrene composition containing a novel flame-retarding, halogenated compound and having not only anti-flame property, 'but also high resistance to weather and blocking.

Other objects and advantages of the present invention will be apparent from the following description.

In accordance with the present invention, the novel halogenated compound has the following formula:

wherein A is an alkoxy group having 1 to 5 carbon atoms, an alkylthio group having 1 to 5 carbon atoms, a car- 'boxylic acid residue having 1 to 5 carbon atoms, a phenoxy group or a phenylthio group or a halogenide of said groups; R is a halogenated alkyl group having 1 to 5 carbon atoms or a halogenated acyl group having 1 to 5 carbon atoms; X is an alkyl group having 1 to 2 carbon atoms, a phenyl group, a halogenide of these groups or a hydrogen atom; Y Y and Y are oxygen or sulfur; m+ru=1-100g mil; and 1150. The said compound is a very effective flame-retarding agent for polystyrene. In view of simplicity of production, compounds having the formula:

more

wherein A, R and m are the same as defined above are preferable.

The group represented by'A includes, for example, methoxy, ethoxy, propoxy, amyloxy, monochloroethoxy, monobromoethoxy, dichloropropoxy, dibromopropoxy, methylthio, ethylthio, propylthio, monochloroethylthio, monobromoethylthio, dichloropropylthio, dibromopropylthio, acetoxy, monochloroacetoxy, monobromoacetoxy, tribromoacetoxy, tribromoethoxy, tribromopropoxy, phenoxy, monochlorophenoxy, monobromophenoxy, trichlorophenoXy, tribromophenoxy, pentachlorophenoxy, phenylthio, monochlorophenylthio, tribromophenylthio and the like. The group represented by 'R includes, for example, dichloropropyl, dibromopropyl, dichlorobutyl, dibromobutyl, tribromoethyl, tribromopropyl, dichloropentyl, dibromopentyl, monochlorodibromobutyl, dichloropropionyl, dibromopropionyl, dichloroisobutyryl, dibromoiso- 3 butyryl, monochlorodibromopropionyl and the like. The .group represented by X includes, for example, methyl, ethyl, monochloromethylene, monobromoethylene, phenyl, monochlorophenyl, tribromophenyl and the like and hydrogen.

The present novel halogenated compound can be prepared by reacting a phenol, alcohol, fatty acid, thiophenol or mercaptane or a halogenide thereof with a glycidyl ether, glycidyl ester or glycidyl thioether or a halogenide thereof and, if necessary, an alkylene oxide or alkylene sulfide or a halogenide thereof and then halogenating the resulting product or by first halogenating the above-mentioned reactants and then reacting the halogenated reactants.

The compound containing at least one trihalogenated propyl group can be prepared by first dehydrohalogenating the corresponding compound containing at least one di-halogenated propyl group and then halogenating the thus dehydrohalogenated compound.

The present flame-retarding compound is represented by the Formula I, in which the two segments may be block-copolymeric or random-copolymeric and may be exchanged with each other.

The present invention further provides an anti-flame composition containing a polystyrene and a flame-retarding compound having the Formula I. The term polystyrene used herein refers to homopolymer of styrene and copolymers of at least 50% by weight of styrene and other unsaturated compounds, such as acrylonitrile, vinyl carbazole', acrylates, methacrylates, vinyl esters, butadiene and the like. The term styrene used herein includes not only styrene per se but also derivatives thereof, such as a-methyl styrene. The present polystyrene composition may be in the form of a foam or non-foam.

The addition of the present flame-retarding compound to a polystyrene may be effected before or after polymerazation of styrene, and in other words, at any time until the final molding of polystyrene. The present flame-retarding compound may be added in an amount of 1 to 20 parts by weight per 100 parts by weight of polystyrene.

In accordance with an embodiment of the present invention, an antiafiame non-foamed polystyrene sheet can be prepared by kneading a polystyrene and a flame-retarding agent on a pair of hot rollers at a temperature of 140 to 150 C. until the flame-retarding agent is uniformly mixed with the polystyrene and then pressing the resulting mixture with a hot press for several minutes to form a sheet. In accordance with another embodiment of the present invention, an anti-flame, foamed polystyrene can be prepared by heating polystyrene particles containing the present flame-retarding agent and propane gas by means of hot water or steam at 100 C. to pre-expand the particles, allowing the preexpanded particles to stand at room temperature for 5 hours or more, and then heating the particles in a mold by means of a super-heated steam at 1 atm. for about 90 seconds to form a foamed polystyrene. The flame-retarding agent may be added to styrene before polymerization, or to polystyrene particles before or after pre-expansion, though it is particularly preferable to add the flame-retarding agent to polystyrene particles before pre-expansion.

The flame-retarding compound of the present invention increases in viscosity and boiling point with the increase of the degree of polymerization, m+n. Further, as shown in the examples which will be described hereinafter, the flame-retarding property and weather-resistance of the present compound are enhanced with the increase of the degree of polymerization. Moreover, the resistance to blocking of pre-expanded polystyrene particles is also enhanced with the increase of the degree of polymerization. The term blocking used above refers to the phenomenon that when foaming agent-containing polystyrcne particles are pre-expanded, a part of the surface of the particles is melted, whereby the particles stick to one another to form lumps. In the production of a foamed polystyrene, pre-expansion is required prior to final expansion in a mold, and hence, if blocking is caused in the pre-expansion, the final expansion in a mold becomes difiicult.

Since the lower the degree of polymerization, m+n, the lower the boiling point of the compound and hence the easier the volatilization of the compound, and since super-heated and pressure steam is used in foaming polystyrene, a low boiling compound is easily steam-distilled off and hence, the anti-flame property of a polystyrene foam containing the compound is lowered. Further, when m+n is low, the resistance to weather and blocking is lowered as is clear from the examples which will be described hereinafter. On the other hand, -when a flame-retarding agent is applied to the surface of polystyrene particles, the lower the viscosity of the compound, the more uniform the resulting coating. In accordance with the inventors research, the range of the degree of polymerization, m+n, of 1 to 100 is suitable for the purpose of the present invention. However, a compound having the Formula I in which In is one, n is zero and sulfur atom is not present in the molecule, is substantially the same is flameretarding effect as the other compound, but tends to cause blocking as compared with the others. Therefore, the range of the degree of polymerization, m, of 2 to 100 is especially suitable for the purpose of the present invention, when the present flame-retarding compound has the Formula I in which n is zero and sulfur atom is not present in the molecule.

In these flame-retarding compounds of the present invention, the compound containing at least one tri-halogenated propyl group is more useful than the corresponding compound containing at least one dihalogenated propyl group when added in the same proportion to the polystyrene. Since the boiling point of the compound containing at least one tri-halogenated propyl group is higher than that of the corresponding compound containing at least one di-halogenated propyl group, the former is more stable than the latter in the process for the production of the foamed-polystyrene. The present flame-retarding compound containing at least one tri-halogenated propyl group may be added in an amount of 0.5 or more parts by weight per 100 parts by weight of polystyrene.

The present flame-retarding compound may be used together with a halogenated hydrocarbon, a halogen-containing alkyl phosphate or phosphite, a metal oxide, an anti-oxidant and a stabilizer, such as di(butyl)tin dilaurate and di(butyl)tin maleate.

The present halogenated compound can be prepared as follows:

Method 1 Into a four-necked flask equipped with a stirrer, a thermometer, a dropping funnel and a reflux condenser were charged 32 parts by weight of methanol and 0.5 part of a BF -Et O catalyst, into which 228 parts by weight of allyl glycidyl ether was dropped through the dropping funel with stirring at a temperature between 40 C. and 50 C. Stirring was thereafter continued for about 1 hour at 60 C. To the resulting reaction product was added 260 parts by weight of carbon tetrachloride, and 320 parts by weight of bromine was then gradually added thereto through the dropping funnel at a temperature of 0 to 10 C. The reaction product was washed with 1% aqueous sodium bicarbonate solution and water to remove free bromine, after which the reaction product was subjected to reduced pressure at a temperature lower than C. to distill off the carbon tetrachloride and water,

whereby the compound of No. 1 in Table l was obtained in a substantially quantitative yield.

In a similar way, the compounds of Nos. 2, 3, 4, 5, 6, 7, 8, 9, 10 and 11 in Table 1 were synthesized.

Method 2 Into a four-necked flask equipped with a stirrer, a thermometer, a dropping funnel and a reflux condenser were charged 58 parts by weight of allyl alcohol and 2.5 parts by weight of a BF Et O catalyst, into which 570 parts by weight of allyl glycidyl ether was then dropped through the dropping funnel with stirring at a temperature between 40 C. and 50 C. Stirring was thereafter continued for about 1 hour at 60 C. 630 parts by weight of carbon tetrachloride was added to the reaction product, into which chlorine gas was then introduced at a temperature of to C. until a pre-determined amount was reached. When the generation of heat was stopped, the reaction product was weighed to find that chlorine addition was quantitatively eflected and the amount of the reaction product was 1050 parts by weight. The reaction product was then washed path a 1% aqueous sodium bicarbonate and water to remove free chlorine, after which the carbon tetrachloride and water were removed at a reduced pressure lower than 20-30 mm. Hg at a temperature lower than 80 C. to obtain the compound of No. 12 in Table l in a substantially quantitative yield.

By a similar procedure, the compound of No. 13 in Table 1 was synthesized.

Method 3 Into a four-necked flask equipped with a stirrer, a thermometer, a dropping funnel and a reflux condenser were charged 58 parts by weight of allyl alcohol and 1.8 parts by weight of a BF Et O catalyst, after which 570 parts by weight of allyl glycidyl ether was dropped thereinto through the dropping funnel with stirring at a temperature between 40 C. and 50 C. Stirring was thereafter continued for about 1 hour at 60 C., after which the temperature was lowered to 40-50 C., at which 44 parts by weight of ethylene oxide was gradually introduced in a gaseous state into the flask. When a predetermined amount of ethylene oxide was introduced, the temperature was slowly elevated to 60 C., at which stirring was continued for about 1 hour. The reaction product was mixed with 630 parts by weight of carbon tetrachloride and the resulting mixture was cooled to a temperature of 0 to 10 C., at which 960 parts by weight of bromine was gradually dropped thereinto through the dropping funnel. The reaction product was washed with a 1% aqueous sodium bicarbonate and water to remove free bromine and then subjected to a reduced pressure of 20 30 mm. Hg at a temperature of 80 C. or less to remove the carbon tetrachloride and water to obtain the compound of No. 14 in Table 1 in a substantially quantitative yield.

In a similar manner, the compounds of Nos. 15 and 16 in Table 1 were synthesized.

Method 4 Into a four-necked flask equipped with a stirrer, a thermometer, a dropping funnel and a reflux condenser were charged 58 parts by weight of allyl alcohol and 1.6 parts by weight of a BF Et O catalyst, after which 456 parts by weight of allyl glycidyl ether was thendropped with stirring into the flask through the dropping funnel at a temperature between 40 C. and 50 C. Stirring was thereafter continued for about 1 hour at 60 C., after which the temperature was again lowered to 40-50 C., at which 60 parts by weight of ethylene sulfide was dropped into the flask through the dropping funnel. After the completion of dropping, the temperature was again elevated to 60 C., at which stirring was further continued for about 1 hour. 570 parts by weight of carbon tetrachloride was thereafter added to the reaction product and the resulting mixture was cooled to 0 to 10 C., at which 800 parts by weight of bromine was dropped thereinto through the dropping funnel. The resulting reaction product was washed with a 1% aqueous sodium bicarbonate and water to remove free bromine, after which the carbon tetrachloride and water were removed at a reduced pressure of 20-30 mm. Hg at a temperature lower than C. to obtain the compound of No. 18 in Table l in a substantially quantitative yield.

In a similar manner, the compounds of Nos. 17, 19, 20, 21 and 22 in Table 1 were synthesized.

Method 5 :Into a four-necked flask equipped with a stirrer, a thermometer, a dropping funnel and a reflux condenser were charged 79.5 parts by weight of ethylene chlorohydrin and 0.9 part by weight of a BF Et O catalyst, after which 342 parts by weight of allyl glycidyl ether was gradually dropped thereinto through the dropping funnel at a temperature between 40 C. and 50 C. Stirring was thereafter continued for about 1 hour at 60 C., after which the temperature was lowered to 405 0 C., at which 154.5 parts by weight of p-chlorostyrene oxide was dropped into the flask through the dropping funnel. After the completion of dropping p-chlorostyrene oxide, the temperature was elevated to 60 C., at which stirring was continued for about 1 hour. 480 parts by weight of carbon tetrachloride was thereafter added to the reaction product and then the temperature was lowered to 0 to 10 C., at which chlorine gas was gradually introduced into the flask. When the generation of heat was stopped, the reaction product was weighed to find that the chlorineaddition was quantitatively effected and the amount of the product was 786 parts by weight. The reaction product was washed with a 1% aqueous sodium bicarbonate and water to remove free chlorine and then subjected to a reduced pressure of 2-030 mm. Hg at a temperature of 80 C. or lower to distill off the carbon tetrachloride and water, whereby the compound of No. 23 in Table 1 was substantially quantitatively obtained.

Method 6 Into a four-necked flask equipped with a stirrer, a thermometer, a dropping funnel and a reflux condenser were charged parts by weight of thiophenol and 1.8 parts by weight of a BR -Et O catalyst and then 504 parts by weight of glycidyl thiomethacrylate was dropped thereinto through the dropping funnel with stirring at a temperature between 40 C. and 50 C., after which stirring was continued at 60 C. for about 1 hour. The temperature was lowered to 4050 C., at which 44 parts by weight of an ethylene oxide gas was introduced thereinto in the same manner as in Method 3. 660 parts by weight of carbon tetrachloride was added to the reaction product, and 210 parts of a chlorine gas was added at a temperature of 0 to 10 C. in the same manner as Method 2. After the chlorine-addition, the reaction product was washed with a 1% aqueous sodium bicarbonate and water to remove free chlorine and then subjected to a reduced pressure of 20-30 mm. Hg at 80 C. or less to distill ofl? the carbon tetrachloride and water, whereby the compound of No. 24 in Table 1 was substantially quantitatively obtained.

Method 7 Into a four-necked flask equipped with a stirrer, a thermometer, a dropping funnel and a reflux condenser were charged 58 uparts by weight of allyl alcohol and 1.8 parts by weight of BF Et O catalyst, after which 342 parts by weight of allyl glycidyl ether was gradually dropped into the flask through the dropping funnel with stirring at a temperature between 40 C. and 50 C. After the completion of dropping allyl glycidyl ether, stirring was continued at 60 C. for about 1 hour, and

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The elementary analysis of the product was as follows.Found (percent): C, 19.11; Br, 70.01. Calcd.

(percent): C, 19.20; Br, 69.84.

The present invention is further explained by the following examples which are only by way of illustration and not byway of limitation.

Example 1.100 parts by weight of a styrene polymer respective mixtures were kneaded on hot rollers at 140 150 C. for 5 minutes. The thus kneaded mixtures were pressed at a pressure of 150 atms. at 140160 C. for 3 minutes, and then subjected to a cooling screw press. According to ASTM-D635-56T, the non-foamed polystyrene sheets withdrawn from the cooling screw press were cut to obtain test samples of 127 x 12.7 x 1.5 mm. which were then subject to burning test. Further, a sample prepared by the same method as above, except that no game-retarding agent was used, was subjected to the same burning test. The results obtained are as shown in Example 2.In a beaker, 100 parts by weight of polystyrene particles number average molecular weight: 180,- 000, each containing propane gas pressurized thereinto, were mixed with a flame-retarding agent as shown in Table 3 in an amount as shown in Table 3 at room temperature to uniformly coat the particles with the agent. The thus coated polystyrene particles were pre-expanded by subjecting them to steam at 100 C. for 1.0 minutes. The thus pre-expanded particles were allowed to stand at room temperature for at least 5 hours, thereafter placed in a mold and heated therein with superheated steam at a pressure of 1.0 atm. (gauge) for seconds, after which the mold is cooled to room temperature to obtain a foamed polystyrene shaped article. The thus obtained article was subjected to a burning test according to Japan Industrial Standards A-951l-l965. The results obtained are as shown in Table 3.

As is clear from theresults shown in Table 3, the present flame-retarding agents are superior in not only flameretarding property but also resistance to Weather and blocking, though the compound having the Formula I in which Y Y and Y are oxygen, m is l and n is 0 is somewhat inferior in resistance to weather and blocking to the other compounds of the present invention.

Further, when a sample free from any flame-retarding agent was subjected to a burning test under the same conditions, the sample began to burn immediately upon contacting with the flame source and was burnt up in Table 2. 18.1 seconds.

TABLE 2 Conventional The present flame-retarding agent fiame-retarder Burning Amt. Amt. Es'tlmarate A R X Y Y Y3 m n (pt.) Name (pt.) tion (em./min.)

CH30- CHzBICHBICHz O O 2 0 O. 0 CH3O- Same as above O O 2 0 0. 0 GlCH OH O -do O 0 4 0 0. 0 Same as above do O O 4 0 0.0 GH;BrGHBrOH;O- do 0 O 3 0 9. 0

guished. Same as above do 0 O 3 0 0.0 Do CH BrCHBrCO- 20 0 0. 0 20 0 8 do 0. 0

Same as above Sam 0 0 3 0 0.0 CHzBlCHBIOHzO- d O 0 0 5 1 0.0 Same as above 0 S O 4 1 0. 0 CzHsS- 0 0 O 20 2 0. 0

CzHbO- I 0 S O 3 1 9. 0

CH2Br(l3O 0- Same as above Same as above -CH2Cl 0 S 0 3 l 7.0 CHzBICHBTCHzO- CHzBICHBICHz- H O O O 25 2 0. 0 Same as above Same as above 0 O 3 0 4 Antimony tri- 0. 8 ...d0 0. 0

ox e. Do do O O 3 0 4 Tn's(2,3-dibr0mo- 0.8 do 0. 0

propyl) phosphate. Do d0 0 0 3 0 5 Bis (2ehl0roethyl) 1. 0 d0 0. 0

vinyl phosphonate. D0 -do 0 0 3 0 4 Tetrabromo- 1. 2 .-do.... 0. O

butane. Do do 0 O 3 0 4 Tetrabromo- 1.2 .do.. 0.0 V ethane. Free from flameretarding agent Burnt 16. 0

O 0 5 m 0 n Q Q 3 h c m N H n m o o 666 50 05 0 j o o wlofio w O 6G a d lounge 2 u n a a iEm m m n m m w 0 0 m 0W0 2 m n 8 0 6 5h .6 2 E3 5 E 82 c a m N a m o w -625 2 5m ofiohmwohm mo M 0 m "M E 23: d 06 n :3 no 2 Sn w 5%-.-.- md ad h 0 O O Q moummoumnmo um Q m o n u a B z xEm h m u 4 H n O O O NOHOMOBEHO o mommgo 3 G 06 Immflmno z {on}... 0 0 m m N cm 0 O O m mo ion-ll m m-O 2 6 ed 26 :3 no @328 pmn flom 1.2.1:-..8: ed o A m 0 O ow 525 8 25m Q i. {095% 2 o a 3 H n o o o ofiohmmoumfio 2 Q a o 6 at. as 3 0 {out}- ad a v o m 0 I O O NO 2 m 3. .5320 2 9 C Q 8 o o ofio mmo m mo 5 O N Q ad w iii-low}... :6 m6 o n O I- O IdEEnSoEaM m 2 2 5 ed :5 no 2 a n m 13:-.- c 6 a6 a m 0 l O l mo mmo mfio OEO EMO M MO d 6 O o nw s mnv Q c6 w {cw-i.- cd m m o 2 "NO OJHOHOHHOHO WO w n o d smart z c Q a n c em o o mmo mfio o mo mmo mfio 5 Q Q d 6 fiw no 2 8 3 5 o o ed o m QOMONO NQO 11 0 o o 38w 5:. no @828 agaaom .2. c d o a o m 13.1.. D Nd w tow-.1. m 0 c4 0 a O lowill an 2 8 5w 5 2 2 m -3 m 6 4 o w o -31- ofioswofio 6 o o 43w 5w E. 828 3.3555 ou m o m m o O -652 3 25m IOQEO w .omago 2 m o w :3 no 2 fiE m iE Efi fifi w o o A Q m mo mmo m mo OSHO amwm m @5803 m3 o fimfi nwav QEE 33v Q M B E N 4 62 3 38 m 582M 3 m P 5 N H-5m EoE coma M wB EEQEH m3 M PBQ Example 4.--Into a 10-1. autoclave were charged 3 kg. of a 1% aqueous polyvinyl alcohol solution and 2 kg. of polystyrene particles (number average molecular weight: 150,000) and then a mixture of 80 g. of the compound of No. 5 or 13 in Table 3 and 1 g. of Noigen EA120 (non-ionic surface active agent made by Dai-ichi Kogyo Seiyaku Kabushiki Kaisha in Japan) was charged thereinto, after which a propane gas was introduced with stirring into the autoclave under a pressure of 14 kg./ cm. for 8 hours. The pressure was thereafter reduced to normal pressure, and the particles were Withdrawn from the autoclave, washed with water and then dried at room temperature. In the same manner as in Example 2, foamed polystyrene shaped articles were obtained and then subjected to burning test and weather-resistance test to find that with both the compounds of Nos. 5 and 13 in Table 3, the burning time was 0.3 second and the articles were self-extinguished and had good weather-resistance.

This example shows that even when a flame-retarding agent is added prior to the addition of a foaming agent, a good result is obtained.

Example 5.Into a solution containing 20,000 parts by weight of water, 40 parts by weight of protective colloid (a copolymer of 95 parts by weight of N-vinyl pyrrolidone and 5 parts by weight of methyl acrylate), 20 parts by weight of sodium pyrophosphate, 35 parts by weight of benzoyl peroxide and 20 parts by weight of ditert.-butyl peroxide, were suspended 10,000 parts by weight of styrene, 300 parts by weight of the compound of No. 9 or 13 in Table 3 and 100 parts by weight of acrylonitrile in an autoclave having a stirrer. The resulting suspension was heated at 70 C. for 20 hours and then at 85 C. for 15 hours to effect polymerization. After heating at 70 C. for 8 hours, 800 parts by weight of pentane was introduced into the autoclave under pressure, 8 hours after which nitrogen was introduced into the autoclave under pressure until the pressure of the autoclave reached 5 atms. (gauge). The polymerization was completed in 35 hours in total. The autoclave was cooled to 30 C., and the produced polymer was Washed and then dried. A propane gas was pressurized into the thus produced styreneacrylonitrile copolymer particles, and expansion was effected in the same manner as in Example 2 to obtain shaped articles, which were then subjected to a burning test and a weather-resistance test to find that with each of the compounds of Nos. 9 and 13, the burning time was 0.0 second, i.e., not burnt and each of the samples had good weather-resistance. This result clearly shows that even when the flame-retarding agent is added prior to polymerization of styrene, a good result is obtained.

Example 6.Using the compounds of Nos. 5, 13 and 14 in Table 3 and the following materials in amounts as shown below, shaped articles were obtained by the same procedure as in Example 5 and subjected to the same test:

Example 61 6-2 6-3 Parts by weight:

Present flame-retarder 1 500 400 3 500 er 20, 000 20, 000 20, 000 Protective colloid 40 4O 40 Sodium pyrophosphate- 20 20 20 Benzoyl peroxide.. 35 35 35 Di-tert.-butyl peroxld 20 20 2O Styrene 7, 070 8, 080 5, 050 Aerylonitrile 3,030 2, 020 5, 050 Pentane 800 8 800 Test results:

0. 0. 4 0. 0 m 0 Weather-resistance Good Good Good 1 Compound 5. 3 Compound 13.

3 Compound 14.

4 Copolymer of 05 parts by weight of N'vinyl pyrrolidone and 5 parts by weight of methyl acrylate.

5 N 0t burnt.

Sell'extingulshed.

Example 7.-7,070 parts by weight of styrene, 3,030 parts by weight of acrylonitrile and 500 parts of the compound of N0. 5 in Table 3 were suspended in a solution containing 20,000 parts by weight of water, 40 parts by weight of a protective colloid (copolymer of parts by weight of N-vinyl pyrrolidone and 5 parts by weight of methyl acrylate), 20 parts by Weight of sodium pyrophosphate, 35 parts by weight of benzoyl peroxide and 20 parts by weight of di-tert.-butyl peroxide in an autoclave having a stirrer. The resulting suspension was heated while being stirred at 70 C. for 20 hours and then at 85 C. for 15 hours to effect polymerization. The autoclave was cooled to 30 C., and the resulting polymer was washed and dried. The produced copolymer of acrylonitrile and styrene was mixed with a foaming agent in the following amount, and the resulting mixture was extruded through a small extruder having a screw of 40 mm. diameter and a ratio of length of diameter of 25 to form a foamed shaped article, which was then subjected to the same test as in Example 2. The results obtained are as follows:

Example 7-1 7-2 Parts by weight:

Acrylonitrile-styrene copolymer 100 Resin added 30 Foaming agent:

Azohexahydrobenzonitrlle 2 Benzene sulionyl hydrazme 3 Extruding temperature, C 150 Burning test, see 0.8 0. 5 Weather-resistance Good G 00d 1 Sell-extinguished.

Weather t1me,sec. Estimate resistance Compound of- No. 5---. 0.0 Not burnt Good. No. 14 0.4 Se1f-extinguished Do. Free from flame-retard 43.0 Burnt Do.

What is claimed:

1. An anti-flame polystyrene composition containing a halogenated compound represented by the formula:

wherein A is a group selected from the class consisting of alkoxy groups containing 1 to 5 carbon atoms, alkylthio groups containing 1 to 5 carbon atoms, carboxylic acid residues containing 1 to 5 carbon atoms, phenoxy group, phenylthio group and halogenides of these groups; R is a group selected from the class consisting of halogenated alkyl groups containing 1 to 5 carbon atoms and halogenated acyl groups containing 1 to 5 carbon atoms; X is a group selected from the class consisting of alkyl groups containing 1 to 2 carbon atoms, phenyl group, halogenides of these groups and hydrogen atom; Y Y and Y are oxygen or sulfur; m-i-n is 1 to 100; m is 1 or more; and n is zero or 1 or more.

2. An anti-flame polystyrene composition according to claim 1 wherein the halogenated compound contains at least one tri-halogenated propyl group.

3. An anti-flame polystyrene composition according to claim 1 wherein the amount of the halogenated compound containing at least one tri-halogenated propyl group is not less than 0.5 part by weight per 100 parts by weight of the polystyrene.

4. An anti-flame polystyrene composition according to claim 1 wherein m+n is 2 to I00; I)! is 2 or more and n is zero or 1 or more.

5. An anti-flame polystyrene composition according to claim 4 wherein the polystyrene composition is in the form of a non-foamed article.

6. An anti-flame polystyrene composition according to claim 4 wherein the polystyrene composition is in the form of a foamed article.

7. An anti-flame polystyrene composition according to claim 4 wherein the amount of the halogenated compound is 1 to 20 parts by weight per 100 parts by weight of the polystyrene.

l 8. An anti-flame polystyrene composition according to claim 4 wherein the polystyrene is a copolymer of styrene and other unsaturated compound.

9. An anti-flame polystyrene composition according to claim 4 wherein the segments -(-CH CHlI( -i and for -clam H2Y3R X of the halogenated compound are both block-polymeric or random-polymeric.

10. An anti-flame polystyrene composition according to claim 4 which further contains antimony trioxide.

11. An anti-flame polystyrene composition according to claim 1 wherein the halogenated compound has the following formula:

wherein A is a group selected from the class consisting of alkoxy groups containing 1 to 5 carbon atoms, carboxylic acid residues containing 1 to 5 carbon atoms, phenoxy group and halogenides of these groups; R is a group selected from the class consisting of halogenated alkyl groups containing 1 to 5 carbon atoms and halogenated acyl groups containing 1 to 5 carbon atoms; and m is 2 to 100.

12. An anti-flame polystyrene composition according to claim 11 wherein the polystyrene composition is in the form of a non-formed article.

13. An anti-flame polystyrene composition according to claim 11 wherein the polystyrene composition is in the form of a foamed article.

14. An anti-flame polystyrene composition according to claim 11 wherein the amount of the halogenated compound is 1 to 20 parts by weight per parts by weight of the polystyrene.

15. An anti-flame polystyrene composition according to claim 11 wherein the polystyrene is a copolymer of styrene and other unsaturated compound.

16. An anti-flame polystyrene composition according to claim 11 which further contains antimony trioxide.

17. An anti-flame polystyrene composition according to claim 11 wherein the halogenated compound contains at least one tri-halogenated propyl group.

18. An anti-fiame polystyrene composition according to claim 11 wherein the amount of the halogenated compound containing at least one tri-halogenated propyl group is not less than 0.5 part by weight per 100 parts by weight of the polystyrene.

References Cited UNITED STATES PATENTS 3,388,079 3/1968 Dickerson et al. 260-475 R 3,372,141 6/1968 Vandenberg 260-475 R 3,539,591 11/1970 Batzer et al. 26045.7 R

SAMUEL H. BLECH, Primary Examiner M. FOELAK, Assistant Examiner U.S. Cl. X.R.

260-45.7 R, 45.7 S, 488 R, 609 A, 609 E, 609 F, 609 R, 611 A, 613 B, 615 B, 615 R, Dig. 24 

